2005-2009 Suzuki VL 1500 Intruder, Boulevard, C90, C90T Service Manual

Wiring diagrams, specifications, and repair sequences for VL1500 Intruder, Boulevard C90/C90T models with engine, transmission, and shaft drive details. Ref: 99500-38040

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Document Details

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Document Number / Seller:
31794 / Joshua Cooper
File Size:
33.72 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Jul 30, 2025

Models Covered & Key Technical Specifications

Suzuki VL1500 (99500-38040) Manual: Suzuki VL1500 Intruder, Boulevard, C90, C90T Overhaul-Reference

Expert Handbook Briefing | Kit.

  • Verified Containment Volume: 15.5 L establishes the fuel tank capacity Architecture.
  • Engineered Fit Tolerances: For optimal operation, 1.0 mm limits the cam chain slack Norms.
  • Prescribed Voltage Specs: 29 psi -- limits the front tire pressure Bounds.
  • Nominal Output Performance: The rear tire requires 36 psi Topology.
  • Defined Net Mass: For proper assembly, 296 kg controls the dry mass Matrix.
  • General Fluid Levels: 10 N·m signifies the starter torque limiter torque Standards.

Manual Description & Preview

Suzuki VL1500 (99500-38040) Manual: Suzuki VL1500 Intruder, Boulevard, C90, C90T Overhaul-Reference

Operational-Scope: Engine Lubrication System // Repair-Classification: Transmission // Operational-Scope: Shaft Drive.

Assessment-Parameter Technical-Path Architecture
Engine Oil Capacities 3.7 L (change) Specifications
Gear Oil 200-220 ml Maintenance
Front Fork Oil 439 ml System Diagrams

Technical content addresses: engine removal, disassembly, reassembly, fuel system, ignition system, chassis, electrical system, transmission, shaft drive, and lubrication system. Key procedures include carburetor synchronization, clutch inspection, brake system maintenance, and gearshift linkage adjustment. It also covers starter motor and generator servicing, ensuring comprehensive coverage for your motorcycle.

Practical procedures are documented, such as engine tune-up and maintenance schedules. The manual documents torque specifications for the final gear case bolts to ensure proper seal compression uniformity.

Steering component information is provided for proper steering adjustment. Inspection guidelines are provided for the front and rear suspension. Alignment specifications are included for the gearshift lever. Reference data is included for engine oil and final gear oil capacities. This manual covers all aspects of your VL1500's maintenance and repair.

FAQ

What is the **required** fluid capacity requirements for the Suzuki VL1500? keyboard_arrow_down

15.5 L is the fuel tank capacity, including reserve. For engine oil changes, 3.7 L is required, increasing to 4.3 L with a filter change, and 5.0 L for an overhaul.

Calculate the **specified** component identification for the engine oil type. keyboard_arrow_down

SF or SG classified (API) engine oil with a viscosity rating of 10W/40 (SAE) is specified for engine oil changes.

What values are **essential** for adjustment procedures on the VL1500, particularly from page 85 onwards? keyboard_arrow_down

Page 85 details the installation of the clutch driven cam onto the clutch sleeve hub, aligning punched marks. For the clutch sleeve hub nut, a torque of 95 N·m is essential.

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